Level with Metal Frame Supporting Protective Outer Body

ABSTRACT

A tool, such as a level, including one or more polymer/plastic body segment, protective cover and/or seal is provided. The covers discussed herein may limit or prevent dirt or construction materials, such as concrete, from entering into the level body. The cover may also be a non-stick material, such as a polymer outer sleeve, that limits the ability of dirt and construction material to adhere to the level. The level may also include scratch resistant vial windows.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

The present application is a continuation of U.S. application Ser. No.17/107,476, filed on Nov. 30, 2020, which is a continuation of U.S.application Ser. No. 16/908,267, filed on Jun. 22, 2020, now U.S. Pat.No. 10,852,133, which is a continuation of U.S. application Ser. No.16/599,644, filed on Oct. 11, 2019, now U.S. Pat. No. 10,697,769, whichis a continuation of U.S. application Ser. No. 15/650,471, filed on Jul.14, 2017, now U.S. Pat. No. 10,520,308, which is a continuation ofInternational Application No. PCT/US2017/037061, filed on Jun. 12, 2017,which claims the benefit of and priority to U.S. Provisional ApplicationNo. 62/354,477, filed on Jun. 24, 2016, U.S. Provisional Application No.62/408,882, filed on Oct. 17, 2016, and U.S. Provisional Application No.62/455,314, filed on Feb. 6, 2017, which are incorporated herein byreference in their entireties.

BACKGROUND OF THE INVENTION

The present invention relates generally to the field of tools. Thepresent invention relates specifically to a tool, such as a level or aspirit level, including one or more polymer body element mounted to aninternal metal frame, the body element may be in the form of a grip, aprotective cover and/or sealing structure. Levels, such as spiritlevels, are used to determine the levelness of a structure, surface orworkpiece. In use, the level is placed on or in contact with a surfaceto be measured, and the user views the location of a bubble within avial relative to markings that indicate the levelness of the structure,surface or workpiece.

SUMMARY OF THE INVENTION

One embodiment of the invention relates to a level including a cover orseal. The level includes a level body having an opening and a level viallocated within the opening and supported by the level body. The levelincludes a window mounted in the opening such that the level vial isviewable through the window. In various embodiments, the level window isformed from a scratch resistant material. In various embodiments, thelevel body extends between a first end and a second end and defines ahollow central area that extends between the first and second ends, andthe level includes a cover, such as an end cap, sealing the level bodyat one of the first end and second end. The cap blocks entry of materialinto the hollow area within the level body. In various embodiments, thelevel includes two end caps, each sealing the open ends of the levelbody. In various embodiments, the end caps are welded to the level body.

In various embodiments, the window is mounted within at least oneopening of the level body in a manner that does not require tools formounting or removing of the window. In various embodiments, the windowis mounted without separate fixation devices such as screws. In someembodiments, a small amount of adhesive may be used for mounting thewindow. In various embodiments, the window is mounted within the atleast one opening via a friction fit arrangement, such as through aninterference fit arrangement, a snap fit arrangement, a press-fitarrangement, etc.

Another embodiment of the invention relates to a level including a coveror seal. The level includes an inner level body having an opening and alevel vial within the opening. The level includes a level window mountedin the opening. The level includes a cover, such as an outer sleevesurrounding at least a portion of the inner level body such that theouter sleeve defines at least a portion of an outermost surface of thelevel. In various embodiments, the sleeve is formed from non-stickmaterial, such as a non-stick polymer material, a polymer material, asilicone material, etc. In various embodiments, the outer sleeve isovermolded around the inner level body.

In various embodiments, the outer sleeve covers at least five of sixsides of the inner level body. In specific embodiments, the outer sleevecovers all six sides of the inner level body such that a base surface ofthe level is defined by a portion of the outer surface of the outersleeve.

In specific embodiments, the outer sleeve covers five of six sides ofthe inner level body and includes an opening through which a surface ofthe inner level body is exposed. In some such embodiments, the innerlevel body is formed from a metal material and defines a lower metalsurface that is exposed through the opening in the outer sleeve, and thelower metal surface forms the base surface of the level.

In specific embodiments, the level has a slightly asymmetricalcross-sectional profile taken across the longitudinal axis of the level.In some such embodiments, the cross-section profile includes at leastfour corners, and one of the four corners is a rounded corner having aradius of curvature larger than a radius of curvature of any of theother three corners. In specific embodiments, the radius of curvature ofthe rounded corner is at least twice the radius of curvature of any ofthe other three corners.

Another embodiment of the invention relates to a level including a levelframe formed from a metal material. The level frame includes a planarbase surface, a vertical wall extending away from the planar basesurface, a vial opening defined at least in part within the verticalwall and a longitudinal axis extending between opposing ends of thelevel frame. The level includes a level vial supported by the levelframe within the vial opening and a plastic outer level body coupled tothe level frame. The outer level body includes a first pair of plasticbody segments coupled to and positioned on opposite sides of thevertical wall of the level frame such that the first pair of plasticbody segments defines part of an exterior surface of the level. Theouter level body includes a second pair of plastic body segments coupledto and positioned on opposite sides of the vertical wall of the levelframe such that the second pair of plastic body segments defines part ofthe exterior surface of the level.

Another embodiment of the invention relates to a level including a levelframe formed from a metal material. The level frame includes a planarbase surface, a vertical wall extending away from the planar basesurface, a vial opening defined at least in part within the verticalwall and a longitudinal axis extending between opposing ends of thelevel frame. The level includes a level vial supported by the levelframe within the vial opening. The level includes an outer level bodycoupled to the level frame. The outer level body includes a supportsection formed from a first plastic material, and the support sectionengages the level frame such that the outer level body is coupled to thelevel frame. The outer level body includes a grip section formed from asecond plastic material and is coupled to an outer surface of thesupport section. The grip section defines at least a part of an exteriorsurface of the level. The second plastic material has a durometer thatis less than a durometer of the first plastic material.

Another embodiment of the invention relates to a level including a levelframe formed from a metal material. The level frame includes an uppersurface, a vertical wall extending downward away from the upper surfaceand a base structure. The base structure includes a bottom wall defininga planar base surface configured to engage a workpiece. The basestructure includes a first sidewall extending upward from a firstlateral edge of the bottom wall defining a first corner edge. The basestructure includes a second sidewall extending upward from a secondlateral edge of the bottom wall defining a second corner edge. The basestructure includes a pair of angled sidewalls each extending from one ofthe first and second sidewalls to a lower end of the vertical wall. Aradius of curvature of an outer surface of the first corner edge is atleast twice the radius of curvature of an outer surface of the secondcorner edge. The level frame includes a vial opening defined at least inpart within the vertical wall and a longitudinal axis extending betweenopposing ends of the level frame. The level includes a level vialsupported by the level frame within the vial opening.

Additional features and advantages will be set forth in the detaileddescription which follows, and, in part, will be readily apparent tothose skilled in the art from the description or recognized bypracticing the embodiments as described in the written description andclaims hereof, as well as the appended drawings. It is to be understoodthat both the foregoing general description and the following detaileddescription are exemplary.

The accompanying drawings are included to provide a furtherunderstanding and are incorporated in and constitute a part of thisspecification. The drawings illustrate one or more embodiments andtogether with the description serve to explain principles and operationof the various embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a level, according to an exemplaryembodiment.

FIG. 2 is an exploded view of the level of FIG. 1 , according to anexemplary embodiment.

FIG. 3 is a perspective view of a level, according to another exemplaryembodiment.

FIG. 4 is an exploded view of the level of FIG. 3 , according to anexemplary embodiment.

FIG. 5 is a top view of the level of FIG. 3 , according to an exemplaryembodiment.

FIG. 6 is a cross-sectional view taken along line 6-6 shown in FIG. 5 ,according to an exemplary embodiment.

FIG. 7 is a cross-sectional view taken along line 7-7 shown in FIG. 5 ,according to an exemplary embodiment.

FIG. 8 is an end view of the level of FIG. 3 , according to an exemplaryembodiment.

FIG. 9 is a perspective view of a level, according to another exemplaryembodiment.

FIG. 10 is a perspective view of a level frame of the level of FIG. 9 ,according to an exemplary embodiment.

FIG. 11 is a rear perspective view of a body segment of the level ofFIG. 9 , according to an exemplary embodiment.

FIG. 12 is a rear perspective view of another body segment of the levelof FIG. 9 , according to an exemplary embodiment.

FIG. 13 is a top view of the body segment of FIG. 11 , according to anexemplary embodiment.

FIG. 14 is an end view of the level of FIG. 9 with end cap removed,according to an exemplary embodiment.

FIG. 15 is a perspective view of a level frame, according to anotherexemplary embodiment.

FIG. 16 is an end view of the level frame of FIG. 15 , according toanother exemplary embodiment.

FIG. 17 is a perspective view of a level, according to another exemplaryembodiment.

FIG. 18 is a top plan view of the level of FIG. 17 , according to anexemplary embodiment.

FIG. 19 is a detailed perspective view of a vial area of the level ofFIG. 17 , according to an exemplary embodiment.

FIG. 20 is a detailed top plan view of the vial area of the level ofFIG. 19 , according to an exemplary embodiment.

FIG. 21 is an end cross-sectional view of the level of FIG. 17 ,according to an exemplary embodiment.

FIG. 22 is a perspective view of a level, according to another exemplaryembodiment.

FIG. 23 is a perspective view of a level, according to another exemplaryembodiment.

FIG. 24 is a perspective view of an end cap for a level, according to anexemplary embodiment.

FIG. 25 is a perspective view of an inner surface of a level bodysegment, according to an exemplary embodiment.

FIG. 26 is a perspective view showing retention/engagement between theend cap of FIG. 24 and the body segment of FIG. 25 , according to anexemplary embodiment.

DETAILED DESCRIPTION

Referring generally to the figures, various embodiments of a level areshown. In general, the levels discussed herein include one or morepolymer body structure, cover, sealing structure, or other feature thatfacilitates use of the level in harsh environments in which material(e.g., concrete, dirt, dust, etc.) may scratch, stick to or enter insideof the body of a conventional level. In various embodiments, levelbodies discussed herein are formed from a hollow piece of material, suchas a hollow piece of metal material (e.g., a hollow piece of extrudedaluminum), and in such embodiments, the level body includes end capswelded or otherwise sealed to the opposing ends of the hollow levelbody. By sealing the ends of the hollow level body, the end caps limitor prevent migration of material (e.g., concrete) into the hollowcentral area within the level body. Applicant has found that byutilizing sealed end caps, the useable lifespan of a level may beincreased by preventing a building material, such as concrete, fromentering the hollow level body, because once solidified, buildingmaterials, such as concrete, may be very difficult to remove from ahollow level body.

Further, the levels discussed herein may utilize one or more vial windowdesign which improves use of the level. In various embodiments, the vialwindow of the level embodiments discussed herein is formed from ascratch resistant (e.g., a high Rockwell hardness plastic material). Invarious embodiments, some levels (e.g., levels used with concrete) areused as scribing/scraping tools, and scratch resistant components,scratch-resistant windows in particular, improve the life span of thelevel. In specific embodiments, the vial windows of the level discussedherein are mounted using an arrangement that allows for removal andmounting of the vial window without use of a tool. In such embodiments,a friction fit, interference fit arrangement, a snap-fit, a post andhole arrangement, mounting tangs, etc. may be used to mount the vialwindow within the level body such that the vial window can be replacedeasily by the user of the level without the need for specializedreplacement tools or complicated replacement kits. In some embodiments,a small amount of adhesive may be used to help hold the window withinthe level body.

In various embodiments, the level embodiments discussed herein mayinclude an outer sleeve or cover layer of a polymer layer (e.g., asilicone or other relatively low durometer material) covering an innerlevel body, frame or skeleton. In such embodiments, the polymer materialof the cover layer is selected to limit or prevent building materials(e.g., concrete) from adhering to the outer surface of the level. Invarious embodiments, the cover layer covers all six major surfaces ofthe inner level body. In other embodiments, the cover layer covers fiveof six sides of the inner level body, and in such embodiments, the coverlayer is not located on the lower base surface of the level body. Thus,in such embodiments, the exposed metal of the frame provides a highlyflat, machined, base surface that may be placed in contact with theworkpiece surface to be leveled during use.

In addition, various embodiments of the level discussed herein may havea slightly asymmetrical cross-sectional profile taken across thelongitudinal axis of the level. Specifically, in such embodiments, thelevel includes at least one rounded (e.g., large radius of curvature)longitudinal edge and three substantially non-rounded edges (e.g., acorner, small radius of curvature edge, etc.). In such embodiments, therounded edge may facilitate gripping/holding of the level, while thesharp corner may be used to scrape or spread a building material, suchas concrete.

Referring to FIG. 1 , a leveling device, such as level 10, is shownaccording to an exemplary embodiment. In general, level 10 includes abody 12 that includes a base surface 14 and an opposing top surface 16.Base surface 14 is a flat, planar surface that engages a surface of aworkpiece to be measured using level 10. In some specific embodiments,base surface 14 is machined to have a flat, flush or planar surfacefollowing formation of body 12 (e.g., following extrusion of a metalforming body 12), and in some embodiments, this machined surface may beanodized.

Referring to FIG. 1 and FIG. 2 , level 10 includes a plurality of boresformed in body 12. As shown in FIG. 2 , level 10 includes a centralopening 18, a first end opening 20 and a second end opening 22. As willbe understood, openings 18, 20 and 22 receive three level vials 24(e.g., bubble vials) which are held in the appropriate orientationrelative to base surface 14 in order for the vials to indicate theangle, levelness, degree of plumb, etc. of the corresponding surface ofa workpiece, as needed for a particular level design or level type.

As shown in FIG. 1 , body 12 of level 10 generally defines alongitudinal axis 26, a width axis 28 and a height axis 30. Surfaces 14and 16 have a length extending generally in the direction oflongitudinal axis 26, and surface 14 resides in a plane parallel to aplane defined by axes 26 and 28. As shown in FIG. 2 , openings 20 and 22each define an axis extending between the left and right sides of level10 in the direction of width axis 28 such that openings 20 and 22 aresubstantially perpendicular to longitudinal axis 26.

Referring to FIG. 2 , level 10 includes a plurality of vial windows,shown as end windows 32 and a central window 34. In general, windows 32are mounted within level body 12 at openings 20 and 22 and provideprotection to level vials 24 within openings 20 and 22, and window 34 ismounted within level body 12 at central opening 18 to provide protectionto level vial 24 within opening 18.

In general, windows 32 and 34 are formed from a hard, scratch resistant,transparent/translucent material to both protect the level vials withinlevel body 12 and to allow the user to easily view the level vialthrough the window. In various embodiments, windows 32 and 34 are formedfrom one or more durable, scratch resistant materials which resistscratching during use in a construction environment. In variousembodiments, windows 32 and 34 are formed from a hard plastic material,such as high density polyethylene, or a hard, strengthened glassmaterial, such as tempered soda lime glass, sapphire lens, analkali-aluminosilicate glass material, such as Gorilla Glass, etc.

In various embodiments, windows 32 and 34 and openings 18, 20 and 22 areconfigured to allow a user to replace the windows 32 and 34 by hand(e.g., without requiring the use of tools, etc.). In variousembodiments, windows 32 and 34 are retained within openings 18, 20 and22 without use of separate fastening components (e.g., screws, bolts,etc.), and in such embodiments, windows 32 and 34 and openings 18, 20and 22 may be shaped and/or sized to form a friction-based fit to holdwindows 32 and 34 in place within level body 12. For example, as shownin FIG. 2 , windows 32 each include a sealing flange 36 which extends ina perpendicular direction away from the front pane 38 of each window 32.In this arrangement, the outer surface of sealing flange 36 issubstantially parallel to the inner surface of level body 12 thatdefines openings 20 and 22, and sealing flange 36 is sized to form afriction fit, specifically an interference fit, with this inner surfaceof level body 12.

In other embodiments, windows 32 and 34 and openings 18, 20 and 22 mayhave other friction fit arrangements to hold windows in place. Forexample, windows 32 and/or 34 may include friction fit posts or tangsreceived within corresponding receiving holes within openings 18, 20and/or 22. In other embodiments, windows 32 and/or 34 may include avariety of other friction fit arrangements, such as snap-fitarrangements.

Referring to FIG. 2 , level 10 includes one or more cover or sealstructure, shown as end caps 40, that seal the ends of level body 12,such that material (e.g., dirt, dust, cement, etc.) is blocked fromentering into level body 12. As shown in FIG. 2 , body 12 of level 10 isa hollow structure defining a hollow central area 42, and in specificembodiments, body 12 of level 10 is an extruded metal tubular structure,such as an extruded aluminum structure, defining hollow central area 42.

In general, end caps 40 are coupled to the ends of level body 12 suchthat entrances to hollow central area 42 are sealed preventing materialfrom entering hollow central area 42. In various embodiments, end caps40 are welded to level body 12 in place over the open ends of hollowcentral area 42, and as shown in the specific embodiment in FIG. 2 ,each end cap 40 includes wall 44 that has an outer surface sized andshaped to seal against the inner surface of level body 12. In specificembodiments, wall 44 is sized to form an interference fit with the innersurface of level body 12, and this interference fit in combination withwelding of end cap 40 to level body 12 provides a robust seal thatlimits or prevents material from entering level body 12.

Referring back to FIG. 1 , level body 12 has a cross-sectional shapetransverse to axis 26 that facilitates use and handling of level 10 invarious applications. In particular, level 10 includes a generallytrapezoidal shaped lower portion 50 and a rounded upper portion 52.Lower portion 50 defines base surface 14 and a pair of opposing,longitudinally extending side surfaces 54 and 56. Side surfaces 54 and56 are planar surfaces and are angled inward such that the width of thelower portion 50 of the level body decreases as the distance from basesurface 14 increases. At the upper ends of side surfaces 54 and 56, aminimum width is reached, and lower body portion 50 transitions intorounded upper portion 52. Thus, in such embodiments, upper surface 16has a curved, and specifically a semi-circular, cross-sectional shaperelative to longitudinal axis 26, and the leftmost and rightmost portionof upper surface 16 transitions into the uppermost portions of sidesurfaces 54 and 56. In various embodiments, rounded upper portion 52provides an easy to use gripping surface. Further, the substantiallyplanar surfaces 54 and 56 are flat surfaces the edges of which areuseful for scraping, and base surface 14 is a flat, planar surface forcontact with a workpiece surface during level measurement.

Referring to FIGS. 3-8 , a leveling device, such as level 100, is shownaccording to an exemplary embodiment. In general, level 100 issubstantially the same as level 10 except for the differences asdiscussed herein. Level 100 includes a body 112 that includes a basesurface 114 and an opposing top surface 116. Base surface 114 is a flat,planar surface that engages a surface of a workpiece to be measuredusing level 100. In some specific embodiments, base surface 114 ismachined to have a flat, flush or planar surface, and in someembodiments, this machined surfaced may be anodized. Similar to level10, level 100 includes a plurality of through bores formed through body112 that each support a level vial (e.g., level vial 24 shown in FIG. 2), and each level vial is held in the appropriate orientation relativeto base surface 114 in order for the vials to indicate the angel,levelness, degree of plumb, etc. of the corresponding surface of aworkpiece, as needed for a particular level design.

Referring to FIG. 3 , level 100 includes a plurality of vial windows,shown as end windows 132 and central window 134. In general, windows 132are mounted within level body 112 such that openings 120 and 122 arecovered, and windows 132 provide protection to level vials withinopenings 120 and 122, and window 134 is mounted within level body 112 atcentral opening 118 to provide protection to level vial within opening118. In various embodiments, windows 132 and 134 are attached withinopenings 118, 120 and 122 via a friction fit, interference fit or otherattachment mechanism that permits removal and replacement of the windowswithout the use of tools and/or are formed from a scratch resistantmaterial, as discussed above regarding level 10.

Referring to FIG. 4 , an exploded view of level 100 is shown accordingto an exemplary embodiment. As shown in FIG. 4 , level body 112 includesan outer protective cover, shown as sleeve 140. In general, sleeve 140is mounted, coupled or attached to inner level body 144 such that theinner surface of sleeve 140 interfaces or directly contacts outersurface 146 of inner level body 144. In this arrangement, sleeve 140 isa protective outer covering including an outer surface 142, and withsleeve 140 mounted to the inner level body 144, outer surface 142 ofsleeve 140 provides the outer most surface of level body 112.

Sleeve 140 has a plurality of openings 148 and 149 that are sized tomatch the width of the outer perimeter of windows 132 and 134,respectively, such that the level vials remain viewable through windows132 and 134 even after sleeve 140 has been applied to inner level body144. In addition, in various embodiments, the thickness of sleeve 140 issuch that the outer surfaces of windows 132 and 134 is even with outersurface 142 of sleeve 140. In specific embodiments, the thickness ofsleeve 140 is substantially the same (e.g., within 1%) as the distancethat windows 132 and 134 protrude from inner level body 144. Thus, asshown in FIG. 3 , this sizing provides that the windows 132 and 134 aresubstantially flush with outer surface 142 of sleeve 140 after sleeve140 is coupled to inner level body 144

In various embodiments, sleeve 140 is formed from a protective materialand provides an additional layer of protection to level 100. In variousembodiments, sleeve 140 is formed from a polymer material withanti-stick properties on outer surface 142 that limits the ability ofdirt, dust, concrete and/or other construction materials to adhere tothe outer surface of level 100. In various embodiments, the material ofsleeve 140 has one or more properties, such as low friction, lowporosity, high hydrophobicity, etc., which may limit the ability ofmaterial to adhere to the outer surface of sleeve 140. In a specificembodiment, sleeve 140 is made from a silicone material. In variousembodiments, sleeve 140 is a contiguous, integral single piece ofpolymer material covering inner level body 144, and in specificembodiments, sleeve 140 is overmolded around inner level body 144.

In various embodiments, referring to FIG. 4 , sleeve 140 covers at leastfive of the six major sides of inner level body 144 (e.g., lower surface150, upper surface 152, end surfaces 154, 156 and side surfaces 158,160). In such embodiments, the outer surface of sleeve 140 is locatedover or exterior to at least five of the six sides of inner level body144 and defines the outermost surface of level 100 at those sides.

In one specific embodiment, sleeve 140 includes a lower region 162 thatis a solid wall of polymer material. In this embodiment, the solid wallat lower region 162 is located outside of and adjacent to lower surface150 of inner level body 144 such that lower surface 150 is covered bysleeve 140. As will be understood, in such embodiments, all six sides ofinner level body 144 are covered by sleeve 140, and in such embodiments,the solid wall located at lower region 162 of sleeve 140 defines thebase surface 114 of the level 100.

In another embodiment, lower region 162 of sleeve 140 is an open area orhole bounded by lower edge 164 of the four generally vertical sidewallsof sleeve 140. In this embodiment, sleeve 140 only covers five of thesix sides of inner level body 144 leaving lower surface 150 exposed. Inthis embodiment, lower surface 150 of inner level body 144 defines theoutermost lower surface of level 100 and as such defines base surface114.

In a specific embodiment, inner level body 144 includes an I-beam shapedframe 166 that supports the various components of level 100, and in thisembodiment, the lower flange 168 of frame 166 defines outer surface 150.In some such embodiments, sleeve 140 with open lower region 162 ismolded over the I-beam shaped frame such that lower flange 168 isexposed through the open lower region 162 of sleeve 140. Thus, in suchembodiments, sleeve 140 with open lower region 162 allows for a rugged,flat metal surface (e.g., outer surface of lower flange 168) to act asbase surface 114 of level 100, while the rest of sleeve 140 provides aprotective and nonstick coating to the other five sides of inner levelbody 144. In some such embodiments, it is believed that providing alevel protected by sleeve 140 while still utilizing a metal surface(such as a machined metal surface) to act as leveling base surface 114provides both protection and non-stick provided by sleeve 140 whileproviding the accurate leveling provided by a highly level, metal basesurface 114. In other embodiments, inner level body 144 may be a boxframe instead of an I-beam shaped frame.

In various embodiments, sleeve 140 is formed over inner level body 144via an overmolding process. Applicant believes that, by utilizing anovermolding process to form sleeve 140, a thin polymer structure can beformed over inner level body 144 even though level body has anasymmetrical cross-sectional shape (see FIG. 7 and FIG. 8 ). Further,Applicant believes that overmolding processes may be particularly wellsuited to forming a robust, yet thin and contiguous polymer sleeve 140.As shown in FIGS. 5-7 , sleeve 140 has a low thickness, T1, relative tothe overall width and length of level 100. In various embodiments, T1 isless than ¼ inch, specifically less than or equal to 1/100 inch and morespecifically is less than or equal to 1/1000 inch. In addition, in theembodiment shown in FIGS. 6 and 7 , sleeve 140 is a substantiallycontiguous integral and uninterrupted piece of molded polymer material,surrounding the sides of inner level body 144 as discussed herein.

Referring to FIG. 8 , the end profile shape of level 100 is shownaccording to an exemplary embodiment. As shown, in FIG. 8 , level 100has a slightly nonsymmetrical end profile, and specifically, level 100is shaped to have at least one rounded corner, shown as rounded corner170. In contrast to the other corners 172, 174 and 176 of level 100,corner 170 has a relatively large radius of curvature, R1, and invarious embodiments, R1 is at least twice, at least 5 times, at least100× the radius of curvature defining one or more of corners 172, 174and/or 176 of level 100. In various embodiments, rounded corner 170provides an easily gripped surface, while sharper corners 172, 174 and176 provide scribing and/or scraping edges to level 100. In particularembodiments, rounded corner 170 improves gripping of level 100 while thelow radius corners 172, 174 and/or 176 provide sharper edges that may beused to spread concrete. In specific embodiments, Applicant believesthat the asymmetrical shape of level 100 is achievable using theovermolding process discussed herein, while such a shape may bedifficult or impossible to form using an extrusion method of the sortcommonly used in level manufacturing.

Referring to FIGS. 9 and 10 , a level 200 is shown according to anexemplary embodiment. Level 200 includes an inner frame 202. In general,frame 202 is a metal frame that supports various components of level 200discussed herein. Similar to the levels discussed above, frame 202defines a planar base surface, shown as flat, base surface 204, that isconfigured to be placed in contact with a workpiece duringlevel/plumbness measurements. In specific embodiments, level 200 is aconcrete level and includes a base structure configured for a variety ofuses, such as scribing, scraping, etc.

In various embodiments, frame 202 is formed from a metal material, andspecifically is formed from an extruded metal material. In a specificembodiment, frame 202 is formed from a magnesium material and inparticular an extruded magnesium material. In some such embodiments,level frame 202 is formed from a single, integral and/or continuouspiece of metal material, such as magnesium material. In specificembodiments, frame 202 is formed from an extruded magnesium metal alloymaterial. In general, Applicant believes that use of magnesium materialsfor frame 202 provides for improved non-stick properties (e.g., relativeto extruded aluminum) which allows frame 202 to remain relatively debrisfree even during use in messy or dirty environments/uses, such asconcrete leveling uses. In some such embodiments, as discussed herein,the magnesium frame 202 is used in conjunction with polymer bodyportions to provide a level with an outer surface that acts as a releasesurface allowing for easy removal of material, dirt, debris, such asconcrete, that may tend to adhere to conventional level bodies. However,in other embodiments, frame 202 may be formed from an extruded aluminummaterial.

Level 200 includes an outer level body, shown as outer body 206,surrounding and coupled to a vertical wall, shown as central wall 208 offrame 202. As will be explained in more detail below, central wall 208is a substantially flat (e.g., having planar major surfaces), verticalwall that is extends away from and/or is positioned perpendicular tobase surface 204 to which outer body 206 is coupled. Level frame 202includes one or more vial opening defined at least in part withincentral wall 208. In the specific embodiment shown in FIG. 10 , level200 includes a plurality of openings 210 formed through central wall 208located near outer ends of frame 202 and a central notch 212. A levelvial 214 is supported in each opening 210, and a third level vial 214 issupported within notch 212. This support is provided via engagementbetween the surfaces of frame 202 that defines openings 210 or notch 212and outer surfaces of level vials 214.

In general, outer body 206 is formed from one or more plastic (e.g.,molded thermoplastic, molded silicone, etc.) material that is mounted toframe 202 to provide a variety of functions discussed herein. Applicanthas found that the plastic material(s) for outer body 206 can beselected to provide both a release surface to facilitate debris removaland at the same time provide improved griping surfaces. In general,outer body 206 is shaped to include an upper, enlarged gripping section216 and to provide additional support and protection to level vials 214.Level 200 includes a pair of end cap structures 218 that are coupled tothe ends of outer body 206 and frame 202. End cap structures 218 plugthe outer ends of level 200 and limit/prevent material, debris, dirt,dust, etc. from entering into level 200.

In the embodiment shown, outer body 206 is formed from a plurality ofsections or segments, each formed from a pair of opposing body sectionsthat are located on opposing sides of central wall 208. In thisarrangement, the body segments define a portion of the exterior surfaceof level 200. Specifically, outer body 206 includes a first pair of bodysections 220, a second pair of body sections 222, a third pair of bodysections 224, a fourth pair of body sections 226, and fifth pair of bodysections 228. As shown best in FIG. 10 , body sections 220, 222, 224,226 and 228 include screw-receiving posts 230, each of which extendthrough a post receiving hole 232 in frame wall 208. To couple bodysections 220, 222, 224, 226 and 228 to frame 202, posts 230 of each bodysegment pass through a corresponding post-receiving hole 232, and ascrew or other fastener is passed through a corresponding screw hole 234on the outer surface of each body segment 220, 222, 224, 226 and 228 totightly couple body sections to frame 202.

In various embodiments, the multiple sections of outer body 206 allowsthe user of level 200 to replace individual sections of outer body 206as may be needed. In addition, Applicant believes that multiple sectionsimprove the ability to assemble outer body 206 on to frame 202 byreducing complexity of aligning posts 230 with post-receiving holes 232(as compared to aligning a single, long plastic component). Further,multiple sections allows for each body section to be molded and mountedto frame 202 with a very high level of positional tolerance, which inturn facilitates the accurate positioning of level vials 214 via bodysegments as discussed below. In specific embodiments, the pairs ofopposing body segments are formed from a plastic material, and in suchembodiments, a substantial portion of the exterior surface of level 200is a plastic surface defined by the plastic material of the bodysegments. In a specific embodiment, at least 50%, and more specificallyat least 75% of the exterior surface of level 200 is defined by theplastic material of outer body 206. Similarly, as can be seen in FIG. 9, outer body 206 extends substantially the entire length of level frame202, and in specific embodiments, the longitudinal length of outer body206 is at least 90% and specifically is 99% of the longitudinal lengthof the level frame 202. In addition, outer body 206 extends a portion ofthe height of level frame 202, and in specific embodiments, the heightof outer body 206 is at least 50% and specifically is 70% of thelongitudinal length of the level frame 202. Applicant believes that alevel, such as the levels discussed herein, that has a relatively largeportion of the outer surface defined by a plastic material, particularlya non-stick plastic material, results in a level with improveddurability and/or cleanability as compared to levels having outer bodysurfaces defined primarily by metal material.

Referring to FIG. 11 , the inner surface of body segment 224 is shown.Body segment 224 includes a pair of curved surfaces, shown as pair ofvertically-orientated semi-cylindrical surfaces 240.Vertically-orientated semi-cylindrical surfaces 240 are curved to matchthe curvature of an outer surface of level vial 214 and are positionedat a high level (e.g., at least 99% aligned, 99.9% aligned, 99.99%aligned, etc.) of horizontal alignment with each other. In variousembodiments, the highly horizontal positioning is achieved viatight/high tolerances in the formation of openings 210 and notch 212.During assembly of level 200, as the pair of opposing body segments 224are fastened onto frame 202, engagement between opposing surfaces 240and level vial 214 provides a final, small amount of positioning tolevel vial 214 to ensure that the level vial is held in the properhorizontal position relative to base surface 204. This engagementprovides for proper vial positioning simply by coupling body segment 224to frame 202 as opposed to level designs that require precise vialfitting operations to ensure that level vials are level/plumb. In otherembodiments, each vial 214 is manually set within the plastic bodysections which allows for high resolution and setting to high levels ofparallelism or perpendicularity relative to the working surface.

Referring to FIG. 12 , inner surface of body section 220 is shownaccording to an exemplary embodiment. It should be noted that bodysections 228 are substantially the same as body section 220 discussedherein, but body sections 228 are mirror images of body sections 220.Similar to body segment 224 discussed above, body segment 220 includes apair of curved surfaces, shown as a pair of horizontally orientatedsemi-cylindrical surfaces 242. Horizontally orientated semi-cylindricalsurfaces 242 are curved to match the curvature of an outer surface oflevel vial 214 and are positioned at a high level (e.g., at least 99%aligned, 99.9% aligned, 99.99% aligned, etc.) of vertical alignment witheach other. During assembly of level 200, as the pair of opposing bodysegments 220 (and body segments 228) are fastened onto frame 202,engagement between opposing surfaces 242 and level vial 214 provides afinal, small amount of positioning to level vial 214 to ensure that thelevel vial is held in the proper vertical position.

Referring back to FIG. 9 , the outer surfaces of body segments 220, 228and 224 include angled or tapered recessed surface sections 250 and 252,respectively, located around or adjacent to level vials 214. In general,recess surface sections 250 and 252 are angled or tapered inward towardlevel vials 214, the medial axis of level 200 and/or toward central wall208. This taper results in a shape to the outer surface of body segments220/228 and 224 that eliminates sharp corners and deep narrow recessesaround level vials 214. This shaping increases the viewing angle oflevel vials 214 within outer body 206, and also limits the ability ofdebris, dirt, dust, etc. to collect within the space around level vials214.

Referring to FIG. 13 , the angled or tapered outer surface of bodysegment 224 is shown and described in more detail. It should beunderstood that surfaces of body segments 220 and 228 include surfaceshaving the tapered shape, angle ranges, etc. as discussed herein.Tapered surface section 252 includes opposing tapered surfaces 256 and258 which are positioned at angles A relative to medial level axis (orlength axis) 254. In various embodiments, angle A is between 15 degreesand 80 degrees, and more specifically between 30 degrees and 60 degrees.The angled surface(s) around level vial 214 are shaped such that thedistance from medial axis 254 to outer surfaces 256 and 258 decrease asthe distance toward the level vial 214 decreases. In addition to theangled or tapered shape, surfaces 256 and 258 are curved surfaces havinga vertically oriented curvature concentric with the curvature ofengagement surfaces 240 (shown in FIG. 11 ). As noted above, thisshaping of the region of surface around vial 214 limits the ability ofdirt, debris, etc. to become lodged in this area and also allows betteraccess for debris removal.

In addition to the gradually sloped angle of surfaces 256 and 258,surfaces 256 and 258 are sized relative to vials 214 to provide openrecessed area shown in the FIGS. In specific embodiments, surfaces 256and 258 each have a length (in a direction parallel to medial axis 254)that is at least 50% of the length of vial 214, and specifically between50% and 200% of the length of vial 214. In various embodiments, the areaof the region bounded by the start of the tapered section is at least 2times as large as the area of the vial opening at the center of bodysegment 224. In various embodiments, angled surfaces 256 and 258 aresymmetric around at least one of the long axis and/or short axis of vial214.

Referring to FIG. 14 , the cross-sectional shape (taken perpendicular tothe medial axis 254) of outer body 206 and frame 202 are shown in moredetail. Outer body 206 includes an enlarged upper section 216 forming agrip along the upper edge of level 200. In addition, frame 202 includesa base structure 260 located on the opposite side (in the verticaldirection) of level frame 202 from grip section 216. Base structure 260is a hollow tubular structure having a plurality of walls 262 havinginner surfaces that define a central channel and an outer horizontalsurface that defines base surface 204. Central wall 208 extends upward,away from and perpendicular to an upper wall 262. Base structure 260defines at least one outer rounded corner 264, similar to rounded corner170 discussed above.

In general, central wall 208 of frame 202 provides a strong, rigid metalsupport for level vials 214 and the plastic outer body 206 while alsoconserving the amount of metal (e.g., compared to typical box levelframe) used in the level. The hollow box configuration of base structure260 provides a strong, bend and deformation resistant base (as comparedto the flange of a typical I-beam level) which helps ensure thelevelness/plumbness of base surface 204 throughout the product life.Further, the hollow box configuration provides a strong, reinforcedstructure for the lower section of level 200 facilitating use of basestructure 260 as a scribing and/or scraping tool. Base structure 260provides one or more of these functions to level 200 while at the sametime providing a relatively light-weight level frame through the hollowstructure provided by base structure 260.

In specific embodiments, base structure 260 has a width, W1, and aheight, H1. In general, base structure 260 is sized and shaped relativeto frame 202 and/or level 200 to provide the various function discussedherein. In specific embodiments, W1 is between 2 times and 10 times thewidth of central wall 208. In a specific embodiment, W1 is substantiallythe same as (e.g., within plus or minus 10% of) the maximum width, W2,of outer body 206. In various embodiments, H1 is between 5% and 30% ofthe total height of level frame 202.

Referring to FIGS. 15 and 16 , a level frame 270 is shown according toan exemplary embodiment. Level frame 270 is substantially the same asframe 202, except as discussed herein. In various embodiments, level 200includes level frame 270 in place of level frame 202.

Level frame 270 includes a cross-beam 272 located at the upper end ofcentral wall 208. Cross-beam 272 extends horizontally outward from theupper end of central wall 208 providing structural support to frame 270.In addition, an upper flange or cross-beam 272 provides additionalsurfaces to which body segments 220, 222, 224, 226 and 228 may beattached.

Level frame 270 includes a five-walled base structure 274. Basestructure 274 includes two angled upper walls 276. Upper walls 276 angleupward toward central wall 208 and away from base surface 204. Invarious embodiments, as compared to a horizontal upper wall, angledupper walls 276 allow for the height of center wall 208 to be reducedwhile maintaining the overall height of level frame 270, which isbelieved to increase the overall strength of base structure 274 and oflevel frame 270 while maintaining total level height. Further, thisangled shape allows for the height of center wall 208 to be reducedwhile allowing the height of the outer, lateral surfaces of the bodysections to have the desired height as shown (e.g., to have the desiredamount of frame 270 covered by the polymer body sections).

Referring to FIG. 17 , a level 300 is shown according to an exemplaryembodiment. Level 300 is substantially the same as level 200 except asdiscussed herein. Similar to level 200, level 300 includes a frame 302.In general, frame 302 is a metal frame that supports various componentsof level 300 discussed herein, and in various embodiments, frame 302 isformed from an extruded metal material, such as an extruded magnesiummetal alloy material, an extruded aluminum alloy material, etc.

Level 300 includes an outer body 304 surrounding and coupled to frame302 and a plurality of level vials 306 supported by and coupled to outerbody 304 and frame 302. In specific embodiments, one or more of levelvials 306 may be a gradient vial that provides a number of lines, eachcorrelated to an amount of tilt off of level. In the embodiment shownand similar to the body segments of level 200, outer body 304 includes aplurality of individual body segments, shown as central body segment310, left end segment 312 and right end segment 314. In general, bodysegments 310, 312 and 314 are generally shaped and coupled to frame 302in the same manner as the segments of outer body 206 discussed above.

Body segments 310, 312 and 314 each include one or more grip section 316supported by a rigid support section 318. In general, grip sections 316are formed from a polymer material that is different than the rigidmaterial of support sections 318. In general, support sections 318 areformed from a relatively rigid and strong polymer material that iscoupled to frame 302 via fasteners as discussed above. In suchembodiments, the rigid polymer material of sections 318 includes one ormore inner surface (see FIG. 20 ) that contacts and engages the metalmaterial of frame 302.

Grip sections 316 are coupled to or mounted to a portion of the outersurface of support sections 318. In this manner, the outermost orexterior surface of body segments 310, 312 and 314 are defined in partby the material of support sections 318 and in part by the material ofgrip sections 316, and in this arrangement, the outer surfaces of gripsections 316 defines a portion of the exterior surface of level 300. Ingeneral, the material of grip sections 316 is different from thematerial of support sections 318 to provide improved gripping/frictionalong the expanded upper portion of level 300.

In various embodiments, grip sections 316 are made from an overmolded orco-extruded grip material such as a soft touch material, a TPE, a TPU, athermoplastic material, etc. In such embodiments, the outer surface ofgrip sections 316 has a higher coefficient of friction than that of thematerial of support sections 318. In various embodiments, the materialof grip sections 316 has a lower durometer than the durometer of thematerial of support sections 318. In various embodiments, the materialof grip sections 316 has a lower modulus of elasticity than the modulusof elasticity of the material of support sections 318. Applicant hasfound that by combining a grip material with the rigid material ofsupport sections, a unique combination of properties, such as improvedgripping, improved durability in a dirty construction environment, andimproved assembly and vial alignment are provided.

In addition to the material characteristics, grip sections 316 arelocated along body segments 310, 312 and 314 in a manner that providesimproved gripping while maintaining the structural rigidity of the outerlevel body 304. Referring to FIG. 17 , grip sections 316 of bodysections 312 and 314 generally extend downward toward the planar basesurface 305 along less than one half of the height of body supportsections 318. Similarly, as shown in FIG. 18 , grip sections 316 arepositioned to curve over toward the upper horizontal surface 320 andcentral wall 342 of frame 302. In this arrangement grip sections 316each have a horizontal surface 322 (e.g., generally upward facingsurface in the orientation of FIG. 17 ) that extends along and generalparallel to horizontal surface 320 of frame 302. Similarly, as shownbest in FIG. 18 , grip sections 316 occupy a significant portion of thelength of level 300. As shown in FIG. 18 , the total longitudinal lengthof horizontal surfaces 322 of all grip sections 316 is at least 40%,specifically at least 50% and more specifically at least 60% of thetotal axial length of upper horizontal frame surface 320. In addition, asubstantial portion of the area of all outer surfaces of level 300 isoccupied by the grip material of grip sections 316. In variousembodiments, grip sections 316 account for between 5% and 75% of thetotal outer surface area of level 300, specifically, grip sections 316account for between 10% and 50% of the total outer surface area of level300, and more specifically, grip sections 316 account for between 15%and 40% of the total outer surface area of level 300. Applicant hasfound that gripping provided by grip sections 316 may be improved byproviding gripping surfaces that surround a substantial portion of theupper expanded section of the level body 304 and that occupies asubstantial portion of the length or surface area of level 300.

Referring to FIGS. 19 and 20 , similar to the shape of the body portionsthat surround the vials of level 200, the sections of body supportportions 318 surrounding level vials 306 are shaped to provide improvedviewability and improved access for cleaning of debris from the areaaround vials 306. As shown in FIG. 19 , the rigid material of bodysupport portion 318 completely surrounds at least one vial 306 along thelateral face of level 300 such that the softer material of grip sectionsis spaced from level vial 306. In this embodiment, the rigid material ofthe body section surrounds and provides structural stability andprotection to level vials 306. It should be understood that, while oneof the vials 306 is shown in FIG. 19 , level 300 may include two or moreareas surrounding level vials 306 as shown in FIG. 19 .

To provide improved viewability and access for cleaning/debris removal,the surfaces of body support portions 318 surrounding level vial 306 areangled and slope inward from the outermost surfaces of level body 304toward level vial 306. In some such arrangements, these angled surfacesare located on each side (e.g., above, below, left and right) of levelvial 306 and, in specific embodiments, the angled surfaces completelysurround level vial 306. As shown in FIG. 19 , the angled surfacessurrounding level vial 306 are inwardly angled such that the widthdimension (e.g., the outer width measured at the outer surface of bodysupport portion 318) of level 300 decreases in a direction toward levelvial 306, and in embodiments where the tapered surfaces completelysurround level vial 306, this decrease in width dimension occurs on allsides of level vial 306.

As shown best in FIG. 19 , body support section 318 includes an upperangled surface 330 and a lower angled surface 332. Upper angled surfaces330 and lower angled surface 332 have longitudinal axes that aresubstantially parallel to the longitudinal axis of level 300. Inaddition, upper angled surface 330 is defined by an angle B relative toa vertical axis and lower angled surface 332 is defined by an angle Crelative to a vertical axis. In various embodiments, angle B and angle Care between 100 degrees and 170 degrees and specifically between 120degrees and 150 degrees. In some embodiments, angle B and C are the sameas each other and in other embodiments, angle B and C are different fromeach other.

Similar to level 200 discussed above, body support section 318 alsoincludes a left (in the orientation of FIG. 19 ) lateral angled surface334 and a right (in the orientation of FIG. 19 ) angled surface 336. Inthis arrangement, angled surfaces 334 and 336 extend in a generallyvertical direction between upper angled surface 330 and lower angledsurface 332, such that the angled surfaces 330, 332, 334 and 336surround level vial 306. Similar to level 200, angled surfaces 334 and336 are defined by angles A as shown in FIG. 20 and discussed above. Inthis arrangement, angled surfaces 330, 332, 334 and 336 can be seen asframing level vial 306 defining an area of gradual transition from themaximum outer width dimensions of level body 304 located outside ofangled surfaces 330, 332, 334 and 336 to the minimum outer widthdimension located at the opening within which level vial 306 is mounted.It should also be understood that while angled surfaces 330, 332, 334and 336 are shown and described as planar tapered surfaces, in otherembodiments, the general decrease in outer width dimension provided bysurfaces 330, 332, 334 and 336 can be provided by a curved surface thatangles or tapers to provide the transition to the body width at levelvial 306 as discussed above.

Referring to FIG. 21 , a cross-sectional view of level 300 showing bodysupport sections 318 coupled to level frame 302 is shown in more detail.Similar to the discussion above regarding level 200, outer body 304 andbody support sections 318 are generally coupled to frame 302 via postand fasteners. However, in addition to coupling and supporting outerbody 304 from frame 302, level 300 is configured to provide a tight fitor seal between outer body 304 and frame 302 which limits or preventsdirt and debris from entering the internal spaces between outer body 304and frame 302.

To provide this engagement/sealing, frame 302 includes an upper flange340 extending perpendicular and in a generally horizontal directionoutward from a vertical central web or wall 342. As shown in FIG. 21 ,the upper section of body portions 318 include opposing L-shapedsurfaces 344 that are sized to abut and seal against the outer surfacesof upper frame flange 340. Each body support section 318 is sized toprovide a tight friction fit or a snap fit between L-shaped surfaces 344and upper flange 340 such that the seam at the interface between thesetwo components is sealed enough to prevent substantial debris, dust,dirt, etc. from entering into level 300. In a specific embodiment, thefit between L-shaped surfaces 344 and upper flange 340 is sufficient toprevent solid debris from entering level 300, but does not form aliquid-tight or air-tight seal.

In addition to sealing along the upper interface between frame 302 andouter body 304, frame 302 includes a base structure 308 that is similarto base structure 260. Base structure 308 includes a pair of sidewalls,shown as a first vertical wall 346 and a second vertical wall 348. Walls346 and 348 extend upward from lateral edges of bottom wall 345 defininga first corner edge 341 and second corner edge 343. Similar to level 100discussed above, first corner edge 341 is a rounded corner having arelatively large radius of curvature that is at least twice the radiusof curvature of second corner edge 343.

Similar to the frame of level 200, frame 302 includes a pair of opposedangled walls 350 angled inwardly from walls 346 and 348 to join basestructure 308 to a lower end of central wall 342. As can be seen in FIG.21 , inner surfaces of bottom wall 345, vertical walls 346 and 348, andangled walls 350 define a cavity 351, and cavity 351 is an open areathat extends between opposing first and second ends of the level frame302. As can be seen in the exemplary embodiment of FIG. 21 , theuppermost surface defined by flange 340 and the planar base surface ofbottom wall 345 are parallel to each other, and central wall 342 isperpendicular to the upper surface and to the planar base surface andbisects the planes defined by both the upper surface and the planar basesurface. In addition, the width of the upper surface is less than awidth of the planar base surface. Applicant has found that this framestructure provides both sufficient rigidity to level 300 while alsoallowing outer body 304 to be firmly and securely mounted to level frame302.

First vertical wall 346 and second vertical wall 348 each provides alower sealing location between frame 302 and the lower edge of outerbody 304. First and second vertical walls 346 and 348 extend verticallyupward from and past the lower end of each angled walls 350. The lowerend of each body support section 318 defines an L-shaped surface 352that is sized to abut and seal against the outer surfaces of verticalwalls 346 and 348. Each body support section 318 is sized to provide atight friction fit or a snap fit between L-shaped surfaces 352 andvertical walls 346 and 348 such that the seam at the interface betweenthese two components is sealed enough to prevent substantial debris,dust, dirt, etc. from entering into level 300. In a specific embodiment,the fit between L-shaped surfaces 352 and vertical walls 346 and 348 issufficient to prevent solid debris from entering level 300, but does notform a liquid-tight or air-tight seal.

In addition to providing a surface against which to seal outer body 304,flange 340 provides downwardly facing and outwardly facing supportsurfaces, and vertical walls 346 and 348 provide both an upward facingand an inwardly facing support surfaces. These support surfaces providesurfaces against which outer body 304 is supported when fastened toframe 302. In specific embodiments, outer body 304 is supported andcoupled to frame 302 at least in part by a snap-fit or friction fitbetween the L-shaped surfaces of outer body 304 and the opposingsurfaces of frame 302. Support in this manner provides the polymermaterial of outer body 304 with a tight, stable fit to frame 302 whichis believed to provide a solid, integral feel to level body 304 despitebeing formed from multiple polymer pieces coupled to frame 302.

In addition to providing sealing, outer body 304 is shaped to provide aneasy to grip and easy to handle structure. Outer body 304 includes anenlarged upper section 354 that defines a maximum width of outer body304 that is located at a vertical position between a vertical mid-pointof central wall 342 and the upper flange 340. Outer body 304 includes aninwardly extending central section 355 that extends inward towardcentral wall 342 and is located below the enlarged upper grip section354. Outer body 304 includes an outwardly extending lower section 356that extends outward toward the upward facing surfaces 358 located atthe upper ends of vertical walls 346 and 348. As can be seen in thespecific embodiments of FIGS. 17 and 21 , grip sections 316 define atleast a portion of the outer surface of the enlarged upper portion 354,and support sections 318 are formed from contiguous pieces of plasticmaterial such that enlarged upper portion 354, inwardly extendingcentral section 355 and the outwardly extending lower section 356 areall part of the same contiguous piece of plastic material.

Referring to FIG. 22 and FIG. 23 , levels 360 and 370 are shownaccording to exemplary embodiments. Levels 360 and 370 are substantiallythe same as level 300, except that levels 360 and 370 have a longerlongitudinal length than level 300, and accordingly, include additionalbody support sections 318. As shown in FIG. 17 , level 300 is arelatively short level and has three body support sections 318 locatedalong each side of frame 302, and in a specific embodiment, level 300has a total longitudinal length of about 24 inches. As shown in FIG. 22, level 360 is a mid-sized level and has five body support sections 318located along each side of frame 302, and in a specific embodiment,level 360 has a total longitudinal length of 48 inches. As shown in FIG.23 , level 370 is a large level and has seven body support sections 318located along each side of frame 302, and in a specific embodiment,level 370 has a total longitudinal length of 72 inches.

Referring to FIGS. 24-26 , an end cap 400 for use with the levelsdiscussed herein is shown and described. In general, as shown in FIG. 17, an end cap 400 is located at each of the opposing ends of level frame302 and seals the ends of the internal cavities within level 300. Asshown in FIGS. 24-26 , end cap 400 is configured for mounting to boththe metal frame 302 and the plastic level body 304.

End cap 400 includes a pair of internal walls 402 and 404 that extendinward in a direction that is substantially parallel to the longitudinalaxis of level 300 when the end cap is mounted to seal the ends of level300. In general, internal walls 402 and 404 are shaped to match thecontours of the outer surface of the body sections to which they areattached. Each internal wall 402 and 404 includes a plurality ofopenings 406 that receive posts 408 that are located along the innersurfaces of left end body segments 312 and of right end body segments314. The engagement between posts 408 and openings 406 acts to hold endcap 400 in place when mounted to outer level body 304. It should beunderstood that while one side of left end body segment 312 is shown inFIGS. 25 and 26 , the inner surfaces of right end body segments 314 aremirror images of left end body segment 312.

In addition to being coupled to outer body 304, end cap 400 includespost 410 that is shaped to be received within cavity 351 defined withinlevel frame 302. In general, post 410 may be sized and/or includeprojections 412 the form a friction fit with the inner surfaces of thewalls that define cavity 351. Thus, in such embodiments, end cap 400 isconfigured with both a first structure (e.g., an upper structure) thatengages and/or couples to the plastic material and a second structure(e.g., a lower structure) that engages and/or couples to the metalmaterial of frame 302.

It should be understood that the figures illustrate the exemplaryembodiments in detail, and it should be understood that the presentapplication is not limited to the details or methodology set forth inthe description or illustrated in the figures. It should also beunderstood that the terminology is for the purpose of description onlyand should not be regarded as limiting.

Further modifications and alternative embodiments of various aspects ofthe invention will be apparent to those skilled in the art in view ofthis description. Accordingly, this description is to be construed asillustrative only. The construction and arrangements, shown in thevarious exemplary embodiments, are illustrative only. Although only afew embodiments have been described in detail in this disclosure, manymodifications are possible (e.g., variations in sizes, dimensions,structures, shapes and proportions of the various elements, values ofparameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter described herein. Someelements shown as integrally formed may be constructed of multiple partsor elements, the position of elements may be reversed or otherwisevaried, and the nature or number of discrete elements or positions maybe altered or varied. The order or sequence of any process, logicalalgorithm, or method steps may be varied or re-sequenced according toalternative embodiments. Other substitutions, modifications, changes andomissions may also be made in the design, operating conditions andarrangement of the various exemplary embodiments without departing fromthe scope of the present invention.

Unless otherwise expressly stated, it is in no way intended that anymethod set forth herein be construed as requiring that its steps beperformed in a specific order. Accordingly, where a method claim doesnot actually recite an order to be followed by its steps or it is nototherwise specifically stated in the claims or descriptions that thesteps are to be limited to a specific order, it is in no way intendedthat any particular order be inferred. In addition, as used herein thearticle “a” is intended to include one or more component or element, andis not intended to be construed as meaning only one.

Various embodiments of the invention relate to any combination of any ofthe features, and any such combination of features may be claimed inthis or future applications. Any of the features, elements, orcomponents of any of the exemplary embodiments discussed above may beutilized alone or in combination with any of the features, elements, orcomponents of any of the other embodiments discussed above.

In various exemplary embodiments, the relative dimensions, includingangles, lengths and radii, as shown in the Figures are to scale. Actualmeasurements of the Figures will disclose relative dimensions, anglesand proportions of the various exemplary embodiments. Various exemplaryembodiments extend to various ranges around the absolute and relativedimensions, angles and proportions that may be determined from theFigures. Various exemplary embodiments include any combination of one ormore relative dimensions or angles that may be determined from theFigures. Further, actual dimensions not expressly set out in thisdescription can be determined by using the ratios of dimensions measuredin the Figures in combination with the express dimensions set out inthis description. In addition, in various embodiments, the presentdisclosure extends to a variety of ranges (e.g., plus or minus 30%, 20%,or 10%) around any of the absolute or relative dimensions disclosedherein or determinable from the Figures.

What is claimed is:
 1. A level comprising: a level frame formed from ametal material, the level frame comprising: a base structure; a verticalwall extending away from the base structure; a vial opening defined atleast in part within the vertical wall; and a longitudinal axisextending between opposing ends of the level frame; a level vialsupported by the level frame within the vial opening; a plastic outerlevel body coupled to the level frame and defining part of an exteriorsurface of the level, the plastic outer level body comprising: a pair ofopposing plastic body segments positioned on opposite sides of thevertical wall and coupled to the level frame; and an end cap positionedat one of the opposing ends of the level frame, the end cap configuredto mount to the level frame and to the plastic outer level body.
 2. Thelevel of claim 1, wherein the end cap includes a pair of internal wallsextending inward in a direction parallel to the longitudinal axis. 3.The level of claim 2, wherein a plurality of posts are located alonginner surfaces of the pair of opposing plastic body segments.
 4. Thelevel of claim 3, wherein each of the pair of internal walls includes aplurality of openings that receive the plurality of posts such thatengagement between the plurality of posts and the plurality of openingsholds the end cap in place when the end cap is coupled to the plasticouter level body.
 5. The level of claim 1, further comprising: a secondpair of opposing plastic body segments positioned on opposite sides ofthe vertical wall and coupled to the level frame at the opposing end ofthe level frame from the pair of opposing plastic body segments; and asecond end cap positioned at the opposing end of the level frame fromthe end cap, the second end cap configured to mount to the level frameand the plastic outer level body.
 6. The level of claim 1, the basestructure of the level frame further comprising: a bottom wall; a pairof opposing sidewalls extending upward from the bottom wall; and a pairof opposing angled walls coupled to the pair of opposing sidewalls andangled inward toward the vertical wall; wherein inner surfaces of thebottom wall, the pair of opposing sidewalls and the pair of opposingangled walls define a cavity extending between opposing ends of thelevel frame.
 7. The level of claim 6, wherein the end cap includes apost extending inward in a direction parallel to the longitudinal axis,the post shaped to be received within the cavity of the base structure.8. The level of claim 7, wherein the post of the end cap includesprojections to engage with the inner surfaces of the bottom wall, thepair of opposing sidewalls and the pair of opposing angled walls thatdefine the cavity.
 9. The level of claim 7, wherein the end cap forms afriction fit with the level frame.
 10. A level comprising: a level framecomprising: a base structure; a vertical wall extending away from thebase structure; a vial opening defined at least in part within thevertical wall; and a longitudinal axis extending between opposing endsof the level frame; a level vial supported by the level frame within thevial opening; an outer level body coupled to the level frame anddefining part of an exterior surface of the level, the outer level bodycomprising: opposing ends of the outer level body; a first pair ofopposing body segments coupled to the level frame; and a second pair ofopposing body segments coupled to the level frame; and a pair of endcaps, each end cap positioned at one of the opposing ends of the levelframe, each end cap configured to couple to the level frame and to theouter level body such that the opposing ends of the outer level body aresealed.
 11. The level of claim 10, wherein each end cap includes a pairof internal walls extending inward in a direction parallel to thelongitudinal axis, each of the pair of internal walls includes aplurality of openings.
 12. The level of claim 11, wherein a plurality ofposts are located along inner surfaces of the first pair of opposingbody segments and the second pair of opposing body segments and whereinthe posts are received within the plurality of openings when the pair ofend caps are coupled to the outer level body.
 13. The level of claim 11,wherein each of the pair of internal walls are shaped to match contoursof an outer surface of at least one of the first pair of opposing bodysegments and the second pair of opposing body segments.
 14. The level ofclaim 10, the base structure comprising a plurality of walls each havingan inner surface that together define a cavity, wherein the pair of endcaps each include a post extending inward in a direction parallel to thelongitudinal axis, the post configured to couple to the cavity.
 15. Thelevel of claim 10, wherein the level framed is formed from a metalmaterial and the outer level body is formed from a plastic material. 16.A level comprising: a level frame formed from a metal material, thelevel frame comprising: a base structure including a plurality of wallseach having an inner surface that together defining a cavity, and anouter horizontal surface defining a planar base surface; a vertical wallcoupled to the base structure and extending away from the planar basesurface; a vial opening defined at least in part within the verticalwall; and a longitudinal axis extending between opposing ends of thelevel frame; a level vial supported by the level frame within the vialopening; and a plastic outer level body coupled to the level frame, theplastic outer level body comprising: a first pair of body segmentscoupled to and positioned on opposite sides of the vertical wall of thelevel frame; and a second pair of body segments coupled to andpositioned on opposite sides of the vertical wall of the level frame;and an end cap configured to engage the plastic outer level body and thelevel frame such that the cavity is sealed.
 17. The level of claim 16,the end cap further comprising: a first structure that engages theplastic outer level body; and a second structure that engages the levelframe.
 18. The level of claim 17, wherein the first structure includesinternal walls extending inward along the longitudinal axis, and whereinthe internal walls include a plurality of openings.
 19. The level ofclaim 18, wherein a plurality of posts are located along the innersurfaces of the first pair of body segments and the second pair of bodysegments, and wherein engagement between the plurality of posts and theplurality of openings holds the end cap in place.
 20. The level of claim17, wherein the second structure is a post extending inward along thelongitudinal axis, and wherein engagement between the post and thecavity holds the end cap in place.